Process of making continuous waterproof sheets and product thereof



June 24, 1930. L. KIRSCHBRAUN 1,767,532

PROCESS OF MAKING CONTINUOUS WATERPROOF SHEETS AND PRODUCT THEREQF Original Filed May 24, 1923 wa/wm Patented June 24, 1930,-

UNITED snares PATENT omlier.

LESTER KIBSOHBRAUN, OF LEONIA, NEW JERSEY, ASSIGN'OR IO THE FLINTKOTE COMPANY, OF BOSTON, MASSACHUSETTS, A CORPORATION OF MASSACHUSETTS raocnss or name conrmuon's wa raaraoor SHEETS Ann .raonnc'r rnnaaor Application aieam ea, 1923, serial ml 641,113. 'gaenewea December as, 1927.

This invention relates to a more particu arly to a process by which heavy gauge paper or board may be formed 2 such as paper .stockor other fibrous pulp,

from comminuted nonfibrous or fibrous material incorporated in a bond of bitumen or like adhesive substances This application is in part a continuation of an earlier application filed b --me, under dateof March 28, 1921, Serial 0. 456,284.

Among the salient objects of the invention are to provide a. process for making heavier paper or sheet board of a substantially heavy gauge comprising cork sawdust or like commmuted materials or fibrous substances such as paper ulp, felted fibres of various sorts, thesebrous and non- I .fibrous materials being incorporated by invention, with means of an adhesive binder and rolled into sheet form; to provide a-process which permitsof the formation of heavy bituminous fibrous compositions containing an excess of the adhesive binder for instance 7 to an amount exceeding the fibrous material c'ondo not need the felting qualities required in the formation of a paper web; to provide a bituminous composition which is of reater thickness, of stronger and stifi'er b0 y and one that has better waterproofing qualities due to the fact that there is a greater amount of waterproof binder incorporated therein.

The single figure in the drawing is a side elevation of the apparatus for use with my arts omitted.

Referring to t e drawing,'-prior to introducing the mixture to be run throu h themachine to the hopper 1, a waterproo binder substance, such. as as halt, rubber orva such as clay, to produce a non-a like waterproof binder, is emulsified in an.

aqueous vehicle with an emulsigying agent, es'ive coatmg about the binder particles and rendering rocess for making a continuous waterproo sheet-and- :the product reduced thereby,'and refers cork, sawdust or the like, in a pug mill and there thoroughly mixed while the stock is disintegrated to the amount best {adapted to produce the sheeted com osition. Generally this is accomplished y lcharging the pug mill or disintegra'tor first with the emulsion, which is in a stiff pasty condition. By.

stiff pasty condition, I refer toan emulsion,

for example, which might contain 40% more or less 0 water and 60% more or less of binder, emulsifying agent or other solids. In other words, it is desirable to have a minimum amount of water in the emulsion and still produce the desired disintegration of the paper stock. The dry paper is then fed into the mixer and disintegrated in the 7 presence of. the emulsion, some of the water of the emulsion being absorbed by the paper.

The paper need not .gerhaps, in some cases, be entirely dry.= T e process is to be distinguished from that type of process in which there is an admixture of the emulsified'pitch and paper stock carrying with it an amount of water many times the amount of solids present such as would be required for preparation for a paper machine. I,

This-transfer of "waterfrom the emulsion to the paper causes the charge to assume a i very thick consistency or body with sufficient internal friction'to readily cause the paper stock to be disintegrated to a .fibrous condition. It will be understood that. there is still sufiicient water present to maintain the emulsion-form of the bituminous binder and 7 care must .be taken tomaintain sufiiclent- .the mass and the asphaltflwill;v.agglomerate which'is no longer to roduce a gummy mass p Should the operaadapted for the rocess.

- tor note. any ten ency for water to separate, I

which is an indication of impending deor remedy this condition.

mulsification, immediate additions of the emulsifying agent, such as clay, will avoid The mixture coming from the pug mill (not shown) is introduced into the hopper 1 and is fed by means of a roll 2 rotatmg'in the bottom of the hopper to an endless belt or carrier 3 operating over rolls 4 and 5. The roll 2 has mounted upon its periphery a plurality of small spike members or projections 6 which serve to feed the stoek'in a uniform manner upon the band or belt 3. The belt is driven in any suitable way in the direction shown by the arrows and the stock laid thereon is passed between upper and lower pressure rolls 7 and 8. The machine is fitted with a series of these pressure rolls, each set having an adjustment for theupper roll by means of which the pressure on the respective sets may be positively controlled. The initial set of rolls will be adjusted so that little pressure will be imposed upon the stock and as it proceeds the pressure will be increased in order that the stock will be formed in a uniform sheet. In this manner, in conjunction with the rate of feed of stock from the hopper the thickness of the sheet may be regulated.

The mixture, comprising a comparatively cool emulsion of adhesive binder and fibrous or non-fibrous stock,.being rolled, out in this of the material with which itis formed. On

emerging from the hot chamber, the sheeted bituminous composition may be run over driers (not shown) or run directlyon to a roll 12 from which the rolled sheets may be placed in storage. Q

The endless belt or band 3 carrying the composition is returned over the roll 5 and passed over a guide roll 13, the surface being subjected to a water s ray at 14 and a stifi brushing by means 0 the rotary brush 15 after'which it passes over the guide roll 16 and is returned to receive an additional charge of the stobk over the roll 4. The particular type of drive has beenpurposely omitted as it would unnecessarily involve the novelty of the invention and its details are of no particular importance other than that it is necessary to drive the belt at a uniform and regulated speed.

It has been found that the thickness of a paper sheet which is produced on a continuous web paper machine is limited and likewise, this limitation holds when an adhesive binder is to be incorporated in the body of the sheet.

In making heavy gauge paper a multilinder machine may be used but even here points. Also, it has been ound that the stock is limited in the amount of the bituminous binder it is able to carry as the binder is supported by the particles of the stock and after a certain point has been .reached, overloading will cause difficulties 0 t e thickness is limited to ap roximately tinuously fed to the upper surface over roll 20 and removed after passin guide rolls over roll 21. fter passing through the pressure rolls enough water has been pressed intov the strip 19 to permit its ready separation from the sheeted composition.

By use of the machine described, a process has been evolved whichpermits the incorporation of amounts of binder to several hundred per cent of the fibrous or nonfibrous material present in the finished composition, i. e., to parts by weight of fiber and other non-bituminous matter there maybe used 200 parts by weight of bituminous binder. This not only produces a .more waterproof product but decreases materially the waste resulting in producing a sheet of this character. It will be noted also that the sheet is not made by combining a series of plies but is run as a single ply through the machine. By emulsifying the adhesive binder rior to mixing it with the stock, the bin er is made non-adhesive and lends itself admirably to the rolling process through which it is run. The fact that the binder and stock are run together, first beingthoroughly mixed, uniformly disperses the former throughout the body of the sheet, making the sheet a com act composition with the binder very umformly incorporated in its body. g

This process is particularly adapted for use where the binder comprises linseed oil with suitable bases, soft stearine pitches and analogous waterproof substances readily colored and which do not lend themselves so readily to the degree of non-adhesiveness requisite to satisfactory manipulation on a pa r machine. i

y means of this process, aroofing sheet or roofing element such as strip shin le or individual shingles may be made whic permits of a much greater strength, thickness and water resisting character, than is the case with the ordinary asphalt saturated roofings of commerce. The ordinary roofthrough the ing felt: of commerce scarcely ever exceeds ninety one thousandths of an inch in thickness and even after saturation with asphalt,

' is still capable of. absorbing ten to twenty per cent of water in twenty four hours. The product made by this process, however, may vary in thickness from a few thousandths of an inch to a half inch or more in thickness, and its water absorbing roperties reduced to as low as three to ve per cent or less in twenty four hours., Also such a roofing element will have a much larger percentage of binder than is the case with the prior art above referred to.

' duced in a relative The a paratus for carrying out the above process orms the subject matter of a separate copen ing application, Serial No. 641,-

114 filed May 24th, 1923.

I claim as my invention:

1. A process of producing an vunfelted compressed sheet comprisin thoroughly intermixing fibrous material introduced in a relatively dry state and a water-repellant binder in the form of a non-adhesive viscous aqueous emulsion to transfer water from the emulsion to the fibrous stock, in sheeting and compressing the mixture while the binder is maintained in an emulsified substantially uniform thickness while maintaining the binder in an emulsion state, and

subsequently causing the binder to permeate the composition b removing the water;

3. A process 0 producing a non-felted compressed sheet which comprises thorfiller material intro-1 oughly intermixingy drystate alidi-a water repellent binder in the form :o'f'a non-adhesive aqueous emulsion to transfer water from the emulsion to, the filler material,

sheeting the composition by compression into a sheet ,of substantially uniform thickness while maintaininggthe binder in an emulsion state, andsubsequently causing the binder to permeate the composition by subjecting the sheet to heat remove the water. i

Y 4. An un'felted water roof composition .-comprisingi a' mixture 0 fibrous stock an a comminuted non-fibrous filler combined- I with a fusible wate roofbituminous binder, and'said binder ing, derived from an emulsion" of waterproofing material and an emulsifying agent for the bituminous binder.

-quentl'yr causing said asphalt to 5.. An unfelted water roof composition comprising a mixture 0 fibrous stock an comminuted resilient filler combined with a fusible waterproof bituminous binder, and said binder being derived from an emulsion of waterproofing material and an emulsifyin agent for the bituminous binder.

6. A com 'ressed unfelted continuous waterproof s eet, comprising a mixture of fibrous stock and comminuted resilient non fibrous filler bonded with a fusible waterproof binder derived from an emulsion of waterproofing material, and an emulsifying agent for the bituminous hinder, the binder being in excess of 150 parts thereof relative to 100 parts by weight of the non-binding material.

A compressed unfelted continuous A,

waterproof sheet, comprising a mixture of fibrous stock and comminuted resilient nonfibrous'filler bonded with a fusible waterproof binder derived from an emulsion of 1 waterproofing material, and an emulsifying agent for the bituminous hinder, the binder being in excess of 150 arts thereof rela-, tive to 100 parts by weig t of the non-bind ing material, and a fibrous backing material. I

8. A process of producing a non-felted com ressed sheet which comprises thorougly intermixing filler material and. a water repellant' fusible binder in the form of a non-adhesive aqueous emulsion, sheeting the composition by com ression into a .sheet of substantially uni orm thickness while maintaining the fusible binder' in an emulsion state, and subsequently causing the fusible binder to permeate the composition by removing the water.

9. A process of producinga non-felted com ressed sheet whichcom rises thoroug l intermixing filler material and heat 1i ue able-asphalt in the form of a nona esive aqueous emulsion, sheeting the mixture by compression into a sheet of uniform ,thickness while maintaining the asphalt in an emulsion state, and subseermeate the sheeted mixture by removing t e water.

. 10. A compressed imfelted vw aterproofed sheet comprising a mixture of comminuted resilient non-fibrous filler bonded with a fusibe waterproofed binder derived from an emulsion of waterproofing material and an emulsifying agent for the binder.

' 11. A'compressed unfelted waterproofed sheet com rising a mixture of comminuted filler bon ed to etherwith acoalesced fusible waterproo ed'binder derived from'an emulsion of bituminous material and an emulsifying agent, the binder being present in proportions greatly in excess to that of 12.- A compressed unfelted sheet comprising'a thorough interadmixture waterproofed of filler material and a water-repellant fusible coalesced binder derived from an aqueous emulsion containing an emulsifying agent rendering the binder non-adhesive until coalesced, said sheet being compressed to substantial uniform thickness and having the water from the emulsion removed to cause the binder to permeate the filler and coalesce.

13. A compressed unfelted waterproofed sheet comprising a mixture of comminuted resilient non-fibrous filler bonded with a fusible waterproofed binder derived from an aqueous emulsion of bituminous material and an inert emulsifying agent for the binder, the water being removed and the binder being coalesced and interlocked with the filler.

LESTER KIRSCHBRAUN. 

